Elk Motor Operating Manual
Elk Motor Operating Manual
Elk Motor Operating Manual
OPERATING MANUAL
(Original Instructions)
These instructions describe the electric motor and explain best practices in motor handling, from initial delivery
to final disposal of the equipment.
These instructions must be followed to ensure safe and proper installation, operation, and maintenance of the
motor.
For your personal safety and to prevent material damage when working on the motor, always observe the
safety instructions and the following safety rules, according to EN 50110-1 ("Working in a voltage-free state).
Disconnect the system. Disconnect the auxiliary circuits, for example anti-condensation heating
Prevent reconnection.
Make sure that the equipment is at zero voltage
Ground and short-circuit the terminals
Cover or isolate nearby components that are still live.
To energize the system, apply the measures in reverse order.
WARNING
Electric motors contain live parts.F atal or severe injuries and substantial material damage can occur if the
required covers are removed or if the motors are not handled, operated, or maintained properly.
Electric motors contain dangerous rotating parts.Fatal or severe injuries and substantial material damage can
occur if the required covers are removed or if the motors are not handled, operated, or maintained properly.
Electric motors have hot surfaces.Fatal or severe injuries and substantial material damage can occur if the
required covers are removed or if the motors are not handled, operated, or maintained properly.
General Definition and technical Properties of the motors:
All of our standard products are designed, manufactured, and tested according to the IEC and EN standards
given below:
Nameplate description;
The nameplate shows the identification, and the most important technical data. The name plate
also defines the limits of proper usage, and manufacturing year of the motors. The first two digits
in the serial number, shows the manufacturing year. For example 15XXXXXXX shows that the
product is manufactured in 2015
Product type codes
2 EL 132 M 4 C - FC - 00 - 000
Additional Motor Features
000…..999 000 : Standard Motor
Electrical Specifications
AA..ZZ Voltage, frequency etc.
Core Length: A, B, C, D
Number of Poles
2: 2 poles 3000 d/d
4: 4 poles 1500 d/d
6: 6 poles 1000 d/d
D: dahlander 4/2 poles constant torque 1500/3000 rpm
E: dahlander 4/2 poles square-law torque 1500/3000
rpm
F: dahlander 8/4 pole constant torque 750/1500 rpm
G: dahlander 8/4 poles square-law torque 750/1500 rpm
S: separate windings 6/4 poles 1000/1500 rpm
T: separate windings 12/4 poles 500/1500 rpm
U: separate windings 12/2 poles 500/3000 rpm
Housing Length
S : Short
M : Medium
L : Long
ELK Motors provides flexibility for different mounting types through their detachable feet which can be
mounted on three sides. This feature allows terminal box assembly on the desired side.Standard motor
terminal box position is on Top
ELK electric motors are manufactured according to International Mounting Standard IEC 60034-7.
2. LIFTING AND STORAGE
Please check delivered product if any damages can exist in transportation process.
Motors above 25 kg weight have lifting lugs or eye bolts. The actual weight of motors is shown on the
nameplate.
Only the main lifting lugs or eyebolts of the motor should be used for lifting the motor.
Use all the lifting eyes on the motors.
Don't use damaged lifting lug.
The storage rooms must provide protection against extreme weather conditions. They must be dry,
free from dust, frost, and vibration, and well ventilated.
Temperature shall be between -20 and 40 .
Motor shaft shall be rotated by hand at least once per year.
Protect motors from direct effect of sun and from gases that have corrosion impact on motors.
Unprotected machined surfaces (shaft-ends and flanges) should be treated against corrosion.
Open any condensation drain holes to drain the condensation (<6 months).
If an anti-condensation heater is provided, switch it on during the machine stoppages.
3. COMMISSIONING
Immediately upon receipt, check the motor for external damage (e.g. shaft-ends and flanges and painted
surfaces) and if found, inform the forwarding agent without delay.
Check all nameplate data, especially voltage and winding connection (star or delta) to ensure that the motor
protection and connection will be properly done.
WARNING
Insulation resistance, corrected to 25°C, must be higher than the reference value given below.
If the reference resistance value is not attained, the winding is too damp and must be oven dried. The oven
temperature should be 90-100 °C for 12 hours.
Safety considerations
The machine is intended for installation and use by qualified personnel, familiar with health and safety
requirements and national legislation.
Safety equipment necessary for the prevention of accidents at the installation and operating site must
be provided in accordance with local regulations.
The temperature of the outer casing of the motor may be too hot to touch during normal operation
and especially after shut-down.
Be aware of rotating parts of the motor.
Do not open terminal boxes while energized.
When aligning and fastening the motor, please bear the following in mind:
The motor shall be mounted on a base, which is rigid enough to prevent distortion and vibration.
Feet and flanges must be fastened securely.
Avoid using rigid coupling measures.
The motors must be carefully aligned. Incorrect alignment can lead to beating failure, vibration, even
shaft fracture.
Coupling halves and pulleys must be fitted on the shaft by using suitable equipment and tools which
do not damage the bearings and seals. Never fit a coupling half or pulley by hammering or by
removing it using a lever pressed against the body of the motor
Excessive belt tension will damage bearings and can cause shaft damage.
If a belt drive is used, make sure that the driving and the driven pulleys are correctly aligned.
The motor should be mounted in such a way that the cooling air should flow to and away from the
motor without obstruction.
For Technical details about the motor dimensions see the catalogue.
Do not exceed permissible loading values for bearings as stated in the product catalogues.
As standard, balancing of the motor has been carried out using half key
Coupling halves or pulleys must be balanced after machining the keyways. Balancing must be done in
accordance with the balancing method specified for the motor.
Before installation, check motor specifications from nameplate if they fitthe requirements of
the load and specification of voltage and frequency.
Measure the insulation resistance between windings and housing. Please check detailed
information in the Checking the insulation resistance section.
WARNING
Note the following safety information before connecting-up the motor:
• Only qualified and trained personnel should carry out work on the motor while it is stationary.
• Disconnect the motor from the power supply and take measures to prevent it being reconnected. This
also applies to auxiliary circuits.
• Check that the motor really is in a no-voltage condition.
• Establish a safe protective conductor connection before starting any work.
• It must be ensured that there are no foreign bodies, dirt, or moisture in the terminal box.
• Keep the inside of the terminal box clean and free from trimmed-off ends of wire.
• Close any additional open cable entries with O-rings or suitable flat gaskets, the terminal box itself
must be sealed so that it is dust and water tight using the original seal.
• When performing a test run, secure the feather keys without output elements.
• Earthing must be carried out according to local regulations before the machine is connected to the
supply voltage.
Terminals and direction of rotation
The standard motors are suitable for clockwise and counter-clockwise rotation.
When the power cables L1, L2, L3 are connected to U1, V1, W1 respectively, the motor shaft turns in clockwise
direction (looking at the shaft from drive side). If two of the power cables are interchanged then the resulting
direction of rotation is counter-clockwise.
Select the connecting cables in accordance with the rated current, ambient temperature, cable gland and
routing method etc. according to IEC/EN 60204-1.
Please observe the tightening torques for cable glands, terminal screws, and other screws.
In addition to the main winding and earthing terminals, the terminal box can also contain connections for
thermistors, heating elements or other auxiliary devices.
The terminal box on standard single speed motors normally contains six winding terminals and at least one
earth terminal. This enables the use of DOL or Y/D starting.
The motors shall be connected in star or delta according to rated voltage given in their nameplate and the
network voltage that they will be connected. For phase to phase 400 V supply, the motors with 230/400V
nameplate values shall be connected in star (Y) and the motors with 400/690V nameplate values shall be
connected in delta ( ).
M 16 2
M20 4
M25 4
Our standard motors have insulation Class F while the temperature rise is Class B. This means the motors will
have a longer service life and work under hard conditions.
Motors are designed to operate at altitudes up to 1000 m and ambient temperature up to 40°C according to
IEC 60034-1. Rated output will change at the % ratings given below for different altitudes and ambient
temperatures.
Up to Up to Up to Up to Up to Up to Up to
ALTITUDE
1000m 1500 m 2000m 2500m 3000m 3500m 4000m
Break
50Hz Rated 60Hz Supply Rated Rated Rated Rated Starting Starting
Down
Voltage Voltage speed Power Torque Current Torque Current
Torque
230V 22OV 1.193 1 0.84 0.97 0.77 0.8 0.8
When operating at speeds above rated speed, for example when used with frequency converters, for
adjustable speed control, noise and vibration levels will be increased and bearing lifetime will be decreased.
The user may require fine balance for better operation above the rated speed. Attention should be paid to the
re-greasing intervals and the grease service life.
120
100
80
60
40
20
0
0 10 20 30 40 50 60 70 80 90 100
Frequency(Hz)
Standard ELK motors are suitable for electronic speed control operations. The frequency range that the motor
can be driven with their fan is shown with blue (continuous) line in the above graph. If the motor will be driven
in a wider range, then an external fan is necessary. By using an external fan the motors can be driven in the
range defined by red (dashed) line.
Do not exceed the speeds given in the table because high speeds increases the level of vibration and noise,
and the bearing lifetime may be reduced.
Maximum safe operating speed (rpm) of three-phase single-speed cage induction motors
Frame Size 2 Pole 4 Pole 6 Pole
<100 5400 3600 2400
112 5200 3600 2400
132 4500 3000 2400
Both IE2 and IE3 efficiency class motors are suitable for operation on frequency converters. Whenever the peak
voltage and the rise time of the pulses at motor terminals are within the limit of the curve given below, there
will be no significant decrease in motor lifetime.
The maximum allowed phase to phase voltage peaks (ÛLL ) at the motor terminals, as a function of the rise time
(tr) of the pulse, is shown in the figure below.
Suitable filters must be incorporated at the converter output to not decrease insulation lifetime, whenever the
peak voltages are not within the limit of the curve.
1,80
1,60
1,40
1,20
Peak Voltage ÛLL (kV)
1,00
0,80
0,60
0,40
0,20
0,00
0 0,2 0,4 0,6 0,8 1 1,2
Rise Time tr (μs)
Limit curves of admissible motor terminal peak voltage for motors up to and including 500 V a.c. rated voltage
6. TROUBLESHOUTING
Motor service and any troubleshooting must be handled by qualified persons who have proper tools and
equipment. Before rectifying any faults, please read the information in the section titled Safety information
7. INSPECTION
Safety instructions
Before starting work on the motors, make sure that the plant or system has been disconnected in a
manner that is compliant with the appropriate specifications and regulations.
In addition to the main currents, make sure that supplementary and auxiliary circuits, particularly in
heating devices, are also disconnected.
A motor with frequency converter supply may energize even if the motor is at standstill.
Certain parts of the motor may reach temperatures above 50 °C. Physical contact with the motor
could result in burn injuries! Check the temperature of parts before touching them.
General inspection
Inspect the motor at regular intervals, at least once a year. The frequency of checks depends on, for example,
the humidity level of the ambient air and on the local weather conditions. This can initially be determined
experimentally and must then be strictly adhered to.
Keep the motor clean and ensure free ventilation airflow. If the motor is used in a dusty environment, the
ventilation system must be regularly checked and cleaned.
Check the condition of shaft seals and replace if necessary.
Check the condition of connections and mounting and assembly bolts.
Check the bearing condition by listening for any unusual noise, vibration measurement, bearing
temperature, inspection of spent grease.
Check if the electrical parameters are maintained.
Check if the winding insulation resistances are sufficiently high.
Check if the cables and insulating parts and components are in a good condition and are not
discolored.
Immediately correct any impermissible deviations that are determined in the inspection.
If the paint is damaged, it must be repaired in order to protect the unit against corrosion.
Pay special attention to bearings when their calculated rated life time is coming to an end.
When signs of wear are noticed, dismantle the motor, check the parts, and replace if necessary. When bearings
are changed, replacement bearings must be of the same type as those originally fitted. The shaft seals have to
be replaced with seals of the same quality and characteristics as the originals when changing bearings.
In the case of the IP 55 motor and when the motor has been delivered with a plug closed, it is advisable to
periodically open the drain plugs in order to ensure that the way out for condensation is not blocked and
allows condensation to escape from the motor. This operation must be done when the motor is at a standstill
and has been made safe to work on.
The calculated life of the bearings of 2Z, 2RS according to ISO 281 is at least 20,000 hours with utilization of the
permissible radial/axial forces. However, the achievable useful life of the bearings can be significantly longer in
the case of lower forces.
Replacing bearings
Special care should be taken with the bearings. These must be removed using pullers and fitted by heating or
using special tools for the purpose.
Do not reuse bearings that have been removed.
Rewinding
Rewinding should always be carried out by qualified repair shops
Assembly
If possible, assemble the motor on an alignment plate.
Avoid damaging the windings protruding out of the stator enclosure when fitting the end Shield
Take care not to damage the cable jacket. Tightening torques must be adapted to suit the type of cable jacket
material in use.
Shaft sealing should be assembled to the right position without any damage
Check the terminal box seals and if required, replace.
Do not forget the foam cover in the cable entry (seal all holes completely and prevent cables from
touching any sharp edges).
Repair any damage to the paint (also on screws/bolts).
Check the tightening torques of all screws, as well as those of screws which have not been unscrewed.
9- SPARE PARTS
2EL and 3EL series motors consist of the following main parts;
When ordering spare parts, the motor serial number, full type designation, and product code, as stated on the
nameplate, must be specified.
For field service, spare parts, and additional information please contact local sales office, if local sales office is
not available please contact our factory, that name and address is given below